Flexible packaging materials and methods of making and using same

ABSTRACT

The present invention relates generally to packaging materials for packaging articles, and more particularly, but not by way of limitation, to a inflatable packaging material which includes, in one embodiment, a plurality of individual strips, strands, or units of material bondably connected to an exterior surface of a flexible, inflatable substrate. The flexible inflatable substrate having a decorative extension and the flexible inflatable substrate forming a cohesive supporting and cushioning unit for use as a packaging material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. Ser. No.11/063,024, filed on Feb. 22, 2005; which is a continuation-in-part ofco-pending U.S. Ser. No. 10/383,413, filed on Mar. 7, 2003, which is acontinuation-in-part of U.S. Ser. No. 09/934,301, filed on Aug. 21,2001, now U.S. Pat. No. 6,534,136, the contents of which are expresslyincorporated herein in their entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to packaging materials forpackaging articles, and more particularly, but not by way of limitation,to a packaging material having a plurality of individual strips,strands, or units of material bondably connected to a flexible substrateto form a cohesive cushioning unit. In one aspect, the present inventionrelates to a flexible, inflatable substrate having a plurality ofindividual strips, strands, or units of decorative material bondablyconnected to the flexible, inflatable substrate to form a cohesivecushioning unit.

2. Brief Description of the Related Art

In the process of shipping an article from one location to another, thearticle is typically placed in a container along with a protectivepackaging material to fill the voids about the article and to cushionthe article during the shipping process. One common protective packagingmaterial includes a plurality of plastic foam, peanut-shaped memberswhich are commonly known as “Styrofoam peanuts.” An advantage in usingStyrofoam peanuts is the ease with which they may be disposed about anarticle positioned in a container by simply pouring the Styrofoampeanuts from a dispenser.

While Styrofoam peanuts have been widely accepted in the packagingindustry, they are not without disadvantages. For example, their lightweight and flowability results in heavier objects gravitating throughthe peanuts to the bottom of the container where the heavier objects canbe damaged. Also, while the flowability of the Styrofoam peanutsfacilitates the introduction of the peanuts into a container, thereceiver of the package is left with having to deal with cleaning up themess left by the peanuts which are easily scattered upon removal of thearticle from the container.

These and other disadvantages associated with the disposal of Styrofoampeanuts, have made paper protective packaging material a popularalternative. Paper is biodegradable, recyclable, and renewable thereforemaking it an environmentally responsible choice. However, like Styrofoampeanuts, paper packaging materials are not without disadvantages. Paper,particularly shredded paper, can be inconvenient to clean up and todispose of due to the lack of cohesiveness of the packaging material.Due to the lack of resiliency in paper products, large amounts of paperare typically required to provide the bulk needed to adequately cushionan object.

Strips of sheet material formed into tufts have also been used for manyyears as a packaging material. More specifically, material known asdecorative grass has been used in fruit baskets, Easter baskets, picnicbaskets, and for other packaging and decorative purposes. The decorativegrass of the prior art has been produced by numerous methods and from avariety of materials such as polymeric materials, paper, cellophane orthe like. Typically, such materials are cut and shredded to producesegments having predetermined dimensions. As such, decorative grass,like Styrofoam peanuts and paper materials described above, can beinconvenient to clean up. Furthermore, the decorative grass can compressand lose its cushioning ability. Large amounts of decorative grass arenecessary, therefore, in order to overcome such compression and/orcompaction deficiencies.

To this end, a packaging material is needed that includes or mimics aplurality of resilient individual strips, strands, or units of materialintertwined with one another or other organic or inorganic materialsthat may be bondably connected to a flexible substrate or substratum soas to form a unitary cushioning unit which overcomes the above-mentioneddisadvantages of prior art packaging materials and has the added benefitof providing a decorative border. It is to such a packaging materialthat the present invention is directed.

BRIEF SUMMARY OF THE INVENTION

The present invention relates, generally, to packaging material for usein filling boxes, baskets, and in any container used to protect, store,and/or ship articles or objects. In one embodiment, the packagingmaterial includes an inflatable flexible substrate having a decorativeborder and a mass of individual, thin, flexible strips, strands, orunits of material intertwined with one another to form a cohesive,resilient tuft. The mass of individual strips, strands, or units ofmaterial may also be attached to one another as well as being disposedon the exterior surface of the inflatable flexible substrate. In analternate embodiment the inflatable flexible substrate is exchanged orreplaced by a cushioning substratum.

The packaging material formed according to the methods disclosed hereinmay be incorporated into a package which additionally includes acontainer, such as a box or basket, and an object positioned within thecontainer and on top of the packaging material. The packaging materialis arranged in the container to support the object when the object isdisposed in the container. The packaging material may be caused to bondto the container and the object may be caused to bond to the packagingmaterial. In use, the packaging material is disposed so as to take upexcess room in the container and protect and/or cushion the object.

The objects, features and advantages of the present invention willbecome apparent from the following detailed description when read inconjunction with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an inflatable packaging material (in adeflated condition) constructed in accordance with the presentinvention, one edge of the uninflatable packaging material beingupwardly turned for illustration purposed only.

FIG. 2 is an exploded view of the inflatable packaging material of FIG.1.

FIG. 2A is a perspective view of the inflatable packaging material ofFIG. 1 in an inflated condition.

FIG. 3 is a perspective view of a strip, strand, or unit of materialused to form a tuft of the inflatable packaging material constructed inaccordance with the present invention.

FIG. 4 is a schematic representation of a system for making the strip,strand, or unit of material of FIG. 3.

FIG. 5 is a perspective view of a basket having the inflatable packagingmaterial disposed therein with a plurality of eggs displayed orcushioned thereon.

FIG. 6 is a perspective view of another embodiment of the inflatablepackaging material in an inflated condition constructed in accordancewith the present invention.

FIG. 7 is a perspective view of a package illustrating the inflatablepackaging material of FIG. 6 disposed therein for cushioning an articleduring a shipping process.

FIG. 8 is an elevational view of another embodiment of a packagingmaterial constructed in accordance with the present invention.

FIG. 9 is a perspective view of the inflatable packaging material ofFIG. 8.

FIG. 10 is a perspective view of a strip, strand, or unit of materialused to form a tuft of the inflatable packaging material of the presentinvention.

FIG. 11 is a perspective view of a basket showing the inflatablepackaging material of FIG. 9 inserted therein and supporting andcushioning eggs.

FIG. 12 is a perspective view of another embodiment of an inflatablepackaging material constructed in accordance with the present invention.

FIG. 13 is an exploded view of the inflatable packaging material of FIG.12.

FIG. 14 is a perspective view of a basket having the inflatablepackaging material of FIG. 12 disposed therein with a plurality of eggsdisplayed or cushioned thereon.

FIG. 15 is a cut away view of a container having a packaging materialconstructed in accordance with the present invention disposed therein.

FIG. 16 is a perspective view of another embodiment of a packagingmaterial constructed in accordance with the present invention.

FIG. 17 is a cross-sectional view of the packaging material of FIG. 16having a plurality of eggs displayed thereon.

FIG. 18 is a perspective view of a basket having the packaging materialof FIG. 17 disposed therein with a plurality of eggs cushioned ordisplayed thereon.

DETAILED DESCRIPTION OF THE INVENTION

Before explaining the various embodiments of the present invention indetail, it is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangement of thecomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments or of beingpracticed or carried out in various ways and as such all suchembodiments and/or equivalents are to be considered as being encompassedwithin the scope and description of the present invention. Also, it isto be understood that the phraseology and terminology employed herein isfor purpose of description and should not be regarded as limiting.

Referring now to the drawings, and more specifically to FIGS. 1-3, aninflatable packaging material 10 constructed in accordance with thepresent invention is illustrated in FIG. 1. The inflatable packagingmaterial 10 includes a tuft 20 comprised of a plurality of individualstrips, strands, or units of material 30 (FIG. 3) bondably connected toa flexible inflatable substrate 40.

The plurality of individual strips, strands, or units of material 30 canbe fabricated from any flexible sheet of material including but notlimited to: paper, crepe paper, polymeric film, laminated polymericfilm, and waxed paper, for example. In one embodiment of the inventionthe laminated polymeric film for example but not by way of limitationcan be at least one clear layer of polymeric film laminated to at leastone iridescent layer of polymeric film so as to provide an iridescenteffect to the laminated polymeric film. The flexible sheet of materialfrom which the plurality of individual strips, strands, or units ofmaterial 30 are fabricated may have printed matter and/or one or moreembossed patterns on at least one side thereof, and the one or moreembossed patterns may be either in register or out of register with theprinted pattern.

The plurality of individual strips, strands, or units of material 30 mayalso be organic or inorganic materials, including leaves, tree bark,branches, dirt, sand, sea shells, or any other type of organic orinorganic material that is capable of being bondably connected to theflexible inflatable substrate 40 to provide a decorative and/orcushioning effect. Furthermore, when the plurality of individual strips,strands, or units of material 30 are fabricated from a flexible sheet ofmaterial, additional inorganic and/or organic materials may be attachedonto or be incorporated into or within the flexible sheet of materialprior to or after its being used to fabricate the plurality ofindividual strips, strands, or units of material 30.

The printed pattern on the flexible sheet of material from which theplurality of individual strips, strands, or units of material 30 arefabricated can be printed in a conventional matter so that, when thesheet of material is slit and cut to produce the strips, strands, orunits of material 30, at least a substantial portion of the strips,strands, or units of material 30 contain at least a portion of theprinted pattern. Further, different colors can be employed to providethe printed pattern on the sheet of material from which the plurality ofindividual strips, strands, or units of material 30 are fabricated.

The sheet of material can also have one or more embossed patterns toprovide the sheet of material with an embossed pattern. Further, thesheet of material can be provided with an embossed pattern as well as aprinted pattern, and the embossed pattern can be either in register orout of register with the printed material and/or printed design.

The plurality of individual strips, strands, or units of material 30, asdescribed above, in one embodiment are commonly referred to as strands,or units of “Easter grass” or “decorative grass”, and such, decorativegrass has been used for many years for filling fruit baskets, Easterbaskets, and picnic baskets and for other decorative and packagingpurposes. The decorative grass of the prior art has been produced bynumerous methods and from a variety of materials, such as those listedabove. Typically, such materials are shredded and cut to producesegmented strips having predetermined dimensions. While the prior artmethods for making decorative grass have been widely accepted, newtechniques for facilitating the use of decorative grass as a packagingmaterial have been sought in view of the fact that decorative grass andother loose shredded packaging material readily fall onto the floor,cling to various objects making them awkward and inconvenient to cleanup, and compact and thereby no longer adequately cushion and/or protectthe items placed thereon.

By connecting the tuft 20 (composed of a plurality of the strips,strands, or units of material 30) to the flexible inflatable substrate40, the clean up problems associated with loose fill materials arealleviated and, because the flexible inflatable substrate 40 is capableof being inflated, the compacting problems with loose fill are alsoalleviated and lesser amounts of material are required. The flexibleinflatable substrate 40 can also be caused to adhere or cohere to anobject and/or the container in which it is placed thereby resulting inan enhanced packaging effect. That is, with loose packaging materials,the object being packaged has a tendency to gravitate through thepackaging material to the bottom of the container thereby reducing theeffectiveness of the packaging material. By using the inflatablepackaging material 10 disclosed herein, the cohesiveness of theinflatable packaging material 10 surrounding the object prevents theobject from gravitating through the container and coming to rest in thebottom of the container.

As best shown in FIG. 2, the flexible inflatable substrate 40, in oneembodiment, is fabricated of a first sheet of material 50 and a secondsheet of material 60. It will be appreciated that the dimensions of theflexible inflatable substrate 40 may be further varied and the shape ofthe flexible inflatable substrate 40 may also, therefore, bevariable—e.g. a circle, square, triangle, heart, an animal shape, afloral shape, etc. The flexible inflatable substrate 40 can be anyflexible sheet of material, such as paper, crepe paper, wax paper,polymeric film, laminated polymeric film, fabric, cellulose, and foil.The flexible inflatable substrate 40 may have printed matter and/or oneor more embossed patterns on at least one side thereof, and the one ormore embossed patterns can be either in register or out of register withthe printed pattern. Different colors can be employed to provide theprinted pattern on the flexible inflatable substrate 40. For example,the printed pattern may be a pictorial representation or color or shapeof the plurality of individual strips, strands, or units of material 30such that when a small amount of the plurality of individual strips,strands, or units of material 30, forming the tuft 20 are bonded to theflexible inflatable substrate 40, the printed pattern fills in the voidsbetween the plurality of individual strips, strands, or units ofmaterial 30 such that it appears that there are few or no actual voidsof the plurality of individual strips, strands, or units of material 30on the flexible inflatable substrate 40 thereby resulting in anaesthetically pleasing inflatable packaging material 10 that appears tobe fully covered with the individual strips, strands, or units ofmaterial 30.

The first sheet of material 50 and the second sheet of material 60 ofthe flexible inflatable substrate 40 may be constructed of a singlelayer of material or a plurality of layers of the same or differenttypes of materials. In addition, any thickness of the first sheet ofmaterial 50 and the second sheet of material 60 of the flexibleinflatable substrate 40 may be utilized with the present invention. Thefirst sheet of material 50 has an outer peripheral edge 70 and thesecond sheet of material 60 has an outer peripheral edge 80. The outerperipheral edge 70 of the first sheet of material 50 is bonded via abonding material 90 to the outer peripheral edge 80 of the second sheetof material 60 to provide and define an expandable interior inflationspace 100. A means 110 for inflating the flexible inflatable substrate40 is placed within the expandable interior inflation space 100.

The means 110 for inflating the flexible inflatable substrate 40 may beany composition or assembly capable of inflating the expandable interiorinflation space 100 to provide and place the inflatable packagingmaterial 10 in its inflated configuration. For example, the means 110for inflating the flexible inflatable substrate 40 may be associatedwith an exterior surface 120 of the flexible inflatable substrate 40 andbe in fluid communication with the expandable interior inflation space100—e.g. a tube capable of being sealed off after air and/or other gasesand/or liquids are passed into the expandable interior inflation space100.

In an alternative embodiment the means 110 for inflating the expandableinterior inflation space 100 is an exothermic reaction assembly wherein,when the exothermic reaction assembly is activated, an exothermicreaction takes place thereby producing a gas capable of filling at leasta portion of the expandable interior inflation space 100 of the flexibleinflatable substrate 40. The exothermic reaction assembly may furtherinclude at least two chambers wherein at least one other chambercontains a weak basic composition and at least one chamber contains aweak acid composition that, when brought into reactive contact with oneanother (e.g. breaking each open to intermix the weak acid compositionwith the weak basic composition), react and form a gaseous reactionproduct that substantially fills the expandable interior inflation space100 of the flexible inflatable substrate 40. The weak basic compositionmay in one embodiment include a Group I or Group II element. Forexample, the weak basic composition may be selected from the groupconsisting of sodium carbonate, calcium carbonate, and combinationsthereof. The weak acid may be vinegar. Although certain compositionshave been set forth as being included in the exothermic reactionassembly, any combination of compositions that, when placed in reactivecontact with one another, produce a gaseous reaction that substantiallyfills the expandable interior inflation space 100 of the flexibleinflatable substrate 40 are considered for use.

Although the flexible inflatable substrate 40 is shown in FIGS. 1-2 asbeing square, the flexible inflatable substrate 40 may be any shape. Forexample, the flexible inflatable substrate 40 may be square,rectangular, circular or any other geometric or fanciful shape. Theshape of the flexible inflatable substrate 40 may even have anirregular, capricious or decorative shape.

To receive the tuft 20, the exterior surface 120 of the flexibleinflatable substrate 40 is coated with a bonding material 130 (which maybe the same as the bonding material 90) such as an adhesive or cohesivewhereby the tuft 20 is caused to bond to the exterior surface 120 of theflexible inflatable substrate 40 as illustrated in FIG. 1. As shown inFIG. 2, the bonding material 130 is disposed on the entire exteriorsurface 120 of the flexible inflatable substrate 40—i.e. on each of thefirst sheet of material 50 and the second sheet of material 60.Alternatively, the bonding material 130 may be applied in such a manneras to substantially coat only one of the first sheet of material 50 orthe second sheet of material 60 of the flexible inflatable substrate 40.It will be further appreciated that the bonding material 130 may bedisposed on the first sheet of material 50 and/or the second sheet ofmaterial 60 in any of a variety of patterns such as strips, circles,dots or any other geometric or biomorphic shape, including decorativedesigns, so long as the bonding material 130 is positioned to functionin accordance with the present invention.

The term “bonding material” as used herein can mean an adhesive,frequently a pressure sensitive adhesive, or a cohesive or anyadhesive/cohesive combination, having adhesive qualities (i.e.,qualities of adhesion or adhesion/cohesion, respectively) sufficient toeffect the connection between portions of the tuft 20 brought intoengagement with the flexible inflatable substrate 40. It will beappreciated that both adhesives and cohesives suitable for the purposesdescribed herein are well known in the art, and both are commerciallyavailable.

FIG. 4 schematically illustrates a system 140 for making the individualstrips, strands, or units of material 30 in accordance with the presentinvention. The system 140 includes a roll of material 150 supported on ashaft 160 having a brake assembly 170 operably connected thereto forcontrolling the rate of withdrawal of the roll of material 150.

The roll of material 150 provides a web of sheet material 180 which ispassed through a slitter 190. The slitter 190 includes a plurality ofspaced apart, stationary knives or other conventional cutting mechanism,which slit or cut the web of sheet material 180 into the individualstrips, strands, or units of material 30 of into a desired width.

The slitted web of sheet material 180 is thereafter passed into a cutter200 where the slitted web of sheet material 180 is cut intopredetermined lengths so as to form the individual strips, strands, orunits of material 30. From the cutter 200, the individual strips,strands, or units of material 30 are conveyed by a conveyor unit 210,which is in the form of a centrifugal blower, to a storage area (notshown) which may be in the form of a suitable bin, packaging machine, orthe like.

As an alternative to forming the individual strips, strands, or units ofmaterial 30 from the roll of material 150, it will be appreciated thatthe individual strips, strands, or units of material 30 may be formedfrom a polymeric film discharged from a film extrusion die which is thenchilled prior to the slitting process. Such a method is disclosed inU.S. Pat. No. 4,292,266, entitled “Process for Making Decorative Grass”,issued to Weder et al. on Sep. 29, 1981, which is hereby expresslyincorporated herein in its entirety by reference.

As illustrated in FIG. 3, the individual strips, strands, or units ofmaterial 30 tend to curl and form folds during the forming process. Itwill be appreciated that these curls and folds contribute to theresiliency and bulkiness or fluffiness of the tuft 20 produced byamassing and intertwining a plurality of the individual strips, strands,or units of material 30. It will be further appreciated that the degreeto which the individual strips, strands, or units of material 30 arecurled and folded can vary dependent on several factors, such as thetype of material used to form the individual strips, strands, or unitsof material 30.

To assemble the inflatable packaging material 10, the individual strips,strands, or units of material 30 are amassed and intertwined to form thetuft 20 and then the tuft 20 is bondably connected to the flexibleinflatable substrate 40 (FIG. 2). Thereafter, and as shown in FIG. 2A,the means 110 for inflating is activated such that the expandableinterior inflation space 100 is inflated and the inflatable packagingmaterial 10 is provided.

FIG. 5 illustrates one use of the inflatable packaging material 10described above. The inflatable packaging material 10 is shown in itsinflated configuration after the means 110 for inflating has beenactivated (i.e. the expandable interior inflation space 100 is inflated)and is disposed in a basket 220 to support a plurality of articles orobjects 230, such as candies or Easter eggs, for display. Morespecifically, the inflatable packaging material 10 is positioned in aninterior 240 of the basket 220 such that the flexible inflatablesubstrate 40 substantially conforms to the contour of the interior 240of the basket 220 thereby lining the interior 240 of the basket 220 withthe individual strips, strands, or units of material 30 forming the tuft20 that is bonded to the flexible inflatable substrate 40 to form theinflatable packaging material 10. If the second sheet of material 60 ofthe flexible inflatable substrate 40 is provided with the bondingmaterial 22, the second sheet of material 60 of the flexible inflatablesubstrate 40 can be bondably connected to the interior 240 of the basket220. In addition, the bonding material 22 on the second sheet ofmaterial 60 of the flexible inflatable substrate 40 causes theinflatable packaging material 10 to remain in place in the basket 220.If the second sheet of material 60 of the flexible inflatable substrate40 is not provided with the bonding material 22, the flexible inflatablesubstrate 40 simply rests in the interior 240 of the basket 220.

FIG. 6 illustrates a modified inflatable packaging material 10 a whichis similar in construction to the inflatable packaging material 10illustrated in FIG. 1 with the exception that the inflatable packagingmaterial 10 a has elongated sidewalls 250 that upon activating the means110 for inflating the expandable interior inflation space 100 providethe inflatable packaging material 10 a with a height 260. A tuft 20 asimilar to the tuft 20 may be connected to the first sheet of material50 and/or the second sheet of material 60 and/or the elongated sidewalls250. It will be appreciated that such a configuration will facilitateinsertion of the inflatable packaging material 10 a into a tall squarecontainer.

For example, FIG. 7 illustrates the inflatable packaging material 10 adisposed in a tall square container 270 so as to provide an interior 280of the tall square container 270 with an inflatable packaging material10 a. The inflatable packaging material 10 a is being used as apackaging material for protecting an article 230 disposed in the tallsquare container 270. In this manner, the tuft 20 a of the inflatablepackaging material 10 a functions to cushion the plurality of articlesor objects 230 during transport.

Referring now to FIGS. 8 and 9, an inflatable packaging material 300constructed in accordance with the present invention is illustrated. Theinflatable packaging material 300 includes a tuft or mass 310 ofindividual, thin, flexible strips, strands or units of material 320,commonly referred to as decorative grass or Easter grass (although thetuft 310 may be fabricated from the same or similar material as tuft 20disclosed hereinabove), disposed upon an exterior surface 330 of anflexible inflatable bag 340. It will be appreciated that tufts ofdecorative grass are often packaged loosely in a bag whereby when it isdesired to utilize the decorative grass, the bag is opened and the grassremoved. The inflatable packaging material 300 is unique in at least onerespect in that the flexible inflatable bag 340 is used in conjunctionwith the tuft 310 on the exterior surface 330 in a manner similar tothat described above in relation to the inflatable packaging material10. That is, in addition to functioning as a substrate for the tuft 310,the flexible inflatable bag 340 is capable of being inflated whileholding the tuft 310 to thereby clean up the problems associated withloose fill materials and provide a more economical and cushioningpackaging material.

The structure of the flexible inflatable bag 340 can be that of anyflexible inflatable bag suitable for being used in a packaging manner.For example, the flexible inflatable bag 340 can be fabricated from asheet of material having a relatively small thickness and being of thetype commonly referred to in the art as a “film”. More particularly, thesheet of material can be a processed, man-made organic polymer filmselected from the group of films consisting of polypropylene, polyvinylchloride, or combinations thereof. However, it is to be noted that thesheet of material may also be constructed from a material selected froma group of materials consisting of plastic film, cellophane, paper,cloth, or combinations thereof. Alternatively, the flexible inflatablebag 340 may be of the type used typically to package sandwiches, such asa Glad™ sandwich bag. The flexible inflatable bag 340 may also be acorsage bag, a balloon, a water storage bag, or any flexible bag orcontainer that is capable of being inflated.

The flexible inflatable bag 340 is characterized as having the exteriorsurface 330 as well as an interior surface 350 with the interior surface350 defining an expandable interior inflation space 360. As best shownin FIG. 8, the exterior surface 330 of the flexible inflatable bag 340is coated with a bonding material 370, such as an adhesive or cohesive,whereby the tuft 310 is caused to bond to the exterior surface 330 ofthe flexible inflatable bag 340 upon being disposed on the flexibleinflatable bag 340. The flexible inflatable bag 340 illustrated in FIG.10 has the bonding material 370 disposed on substantially the entireexterior surface 330. Alternatively, the bonding material 370 may beapplied in such a manner as to substantially coat only a portion of theexterior surface 330 of the flexible inflatable bag 340. It will befurther appreciated that the bonding material 370 may be disposed on theexterior surface 330 of the flexible inflatable bag 340 in any of avariety of patterns such as strips, circles, dots or any other geometricor biomorphic shape, including decorative designs, so long as thebonding material 370 is positioned to function in accordance with thepresent invention. The tuft 310 is disposed on the flexible inflatablebag 340 in any manner which is known in the art, such as automaticallypassing the tuft 310 through a tube (not shown) which is disposedgenerally above the flexible inflatable bag 340, or the flexibleinflatable bag 340 may be dipped, rolled, or dropped into a plurality oftufts 310 such that the tufts 310 stick to the exterior surface 330 ofthe flexible inflatable bag 340.

Upon the tuft 310 being placed onto the flexible inflatable bag 340, thetuft 310 will bondingly connect to the exterior surface 330 of theflexible inflatable bag 340 via the bonding material 370. After the tuft310 has been disposed onto the flexible inflatable bag 340, the flexibleinflatable bag 340 may be inflated via a means 380 for inflating theflexible inflatable bag 340 disposed in the expandable interiorinflation space 360 to form the inflatable packaging material 300. Themeans 380 for inflating the flexible inflatable bag 340 is similar inconstruction to the means 110 for inflating the flexible inflatablesubstrate 40 of the inflatable packing material 10 as describedhereinabove. It should be appreciated that with the tuft 310 disposed onthe flexible inflatable bag 340, the flexible inflatable bag 340 can bestored, transported, and displayed in a conventional manner when it isin its inflated configuration or in its non-inflated configuration.

In addition to, or as an alternative to coating the exterior surface 330of the flexible inflatable bag 340 with the bonding material 370, thetuft 310 may be connected to the exterior surface 330 of the flexibleinflatable bag 340 via a bonding material 390 (FIG. 10) provided on theindividual strips, strands, or units of material 320 making up the tuft310. The bonding material 390 may be an adhesive or cohesive whereby theindividual strips, strands, or units of material 320 are caused to sticktogether when a plurality of the strips, strands, or units of material320 are amassed to form the tuft 310. The strips, strands, or units ofmaterial 320 may be spot coated wherein the bonding material 390 isdisposed as randomly disposed spots on the individual strips, strands,or units of material 320. It will be appreciated, however, that thebonding material 390 may be applied in such a manner as to substantiallycover the strips, strands, or units of material 320. Further, thebonding material 390 may be disposed on the strips, strands, or units ofmaterial 320 in any of a variety of other patterns such as circles, dotsor any other geometric or biomorphic shape, including decorativedesigns, so long as the bonding material 390 is positioned to functionin accordance with the present invention.

FIG. 11 illustrates one use of the inflatable packaging material 300described above. The inflatable packaging material 300 is shown disposedin a basket 400 and supporting a plurality of articles or objects 410,such as candies or Easter eggs, for display. More specifically, aportion of the flexible inflatable bag 340 has been removed so as toexpose the tuft 310 while the tuft remains connected to the exteriorsurface 330 of the flexible inflatable bag 340.

With the flexible inflatable bag 340 inflatable, the inflatablepackaging material 300 may then be positioned in an interior 420 of thebasket 400 such that the flexible inflatable bag 340 substantiallyconforms to the contour of the interior 420 of the basket 400 andthereby lines the interior 420 of the basket 400 with the plurality ofarticles or objects 230 being supported by the tuft 310 and the tuft 310being held in the basket 400.

It will be appreciated that coating the tuft 310 with a bonding materialin the manner discussed above provides an additional advantage ofimproved object support. That is, with loose packaging materials,objects being packaged often have a tendency to gravitate through thepackaging material to the bottom of the container thereby reducing theeffectiveness of the packaging material. By providing a bonding materialon the individual strips, strands, or units of material 320 making upthe tuft 310, the cohesiveness of the tuft 310 supporting the pluralityof articles or objects 410 prevent the plurality of articles or objects410 from gravitating through the tuft 310.

As shown in FIG. 8, the exterior surface 330 of the flexible inflatablebag 340 may also be provided with a bonding material 430. In thisinstance, the bonding material 430 would be provided with a backing orrelease strip 440 to protect the bonding qualities of the bondingmaterial 430 and to prevent adjacent bags from bonding to one anotherduring shipping and storage. By providing the exterior surface 330 ofthe flexible inflatable bag 340 with the bonding material 430 (as shownin FIG. 8), the exterior surface 330 of the flexible inflatable bag 340can be bondably connected to an interior 420 of the basket 400 to holdthe inflatable packaging material 300 in the basket 400. In addition,the bonding material 430 on the exterior surface 330 of the flexibleinflatable bag 340 will cause overlapping portions of the flexibleinflatable bag 340 to be bondably connected so as to retain the shape ofthe flexible inflatable bag 340 after it has been shaped to conform tothe contour of the interior 240 of the basket 400. If the exteriorsurface 330 of the flexible inflatable bag 340 is not provided with thebonding material 430, the flexible inflatable bag 340 is simply shapedto conform to the contour of the interior 420 of the basket 400.

In using the inflatable packaging material 300 described above, itshould be appreciated that a single unit of the inflatable packagingmaterial 300 can be used in a container or on a surface or multipleunits of the inflatable packaging material 300 can be used by eithernesting one inflatable packaging material 300 into another inflatablepackaging material 300 or otherwise layering one inflatable packagingmaterial 300 on top of another inflatable packaging material 300,thereby increasing the volume and/or density of the inflatable packagingmaterial 300.

Referring to FIGS. 12-14, shown therein is an inflatable packagingmaterial 10 b constructed in accordance with the present invention. Theinflatable packaging material 10 b is similar in construction to theinflatable packaging material 10. The inflatable packaging material 10 bincludes a flexible inflatable substrate 40 b, a decorative extension 12b and the tuft 20 b. The tuft 20 b is similar to the tuft 20 a. The tuft20 b is connected to the flexible inflatable substrate 40 b in a mannersimilar to the manner in which the tuft 20 is connected to the flexibleinflatable substrate 40. The tuft 20 b includes the plurality ofindividual strips, strands, or units of material 30 b similar to theplurality of individual strips, strands or units of material 30 and canbe, for instance, bondably connected to the flexible inflatablesubstrate 40 b. The flexible inflatable substrate 40 b includes anexterior surface 41 b, and interior surface 42 b, an inner area 43 bsubstantially surrounded by an inner seal 44 b and a distal edge 45 b.In one embodiment the decorative extension 12 b extends outwardly fromat least a portion of the inner seal 44 b to at least a portion of thedistal edge 45 b.

The flexible inflatable substrate 40 b is fabricated of a first sheet ofmaterial 50 b and a second sheet of material 60 b similar inconstruction to the first sheet of material 50 and the second sheet ofmaterial 60, respectively. It will be appreciated that the dimensions ofthe flexible inflatable substrate 40 b may be varied and the shape ofthe flexible inflatable substrate 40 b may be variable—e.g. a circle,square, triangle, heart, an animal shape, a floral shape, etc. The firstsheet of material 50 b and the second sheet of material 60 b can be anyflexible sheet of material, such as paper, wax paper, polymeric film,laminated polymeric film, fabric, cellulose, and foil. The first sheetof material 50 b and the second sheet of material 60 b may have printingand embossing on all or a part of at least one side thereof, and theembossing can be either in register or out of register with theprinting. Different colors can be employed to provide the printing onthe first sheet of material 50 b and the second sheet of material 60 b.For example, the printing may be a pictorial representation, or color,or shape of the plurality of individual strips, strands, or units ofmaterial 30 b such that when a small amount of the plurality ofindividual strips, strands, or units of material 30, forming the tuft 20b are bonded to the flexible inflatable substrate 40 b, the printingfills in the voids between the plurality of individual strips, strands,or units of material 30 b. The printing provides the illusion that thereare few or no actual voids of the plurality of individual strips,strands, or units of material 30 b on the flexible inflatable substrate40 b thereby resulting in an aesthetically pleasing inflatable packagingmaterial 10 b that appears to be fully covered with the individualstrips, strands, or units of material 30 b.

The first sheet of material 50 b and the second sheet of material 60 bof the flexible inflatable substrate 40 b may be constructed of a singlelayer of material or a plurality of layers of the same or differenttypes of materials. In addition, any thickness of the first sheet ofmaterial 50 b and the second sheet of material 60 b may be utilized withthe present invention. The first sheet of material 50 b has an innerperimeter 52 b, an inner area 53 b surrounded by the inner perimeter 52b, an outer peripheral edge 54 b and an outer area 56 b between theinner perimeter 52 b and the outer peripheral edge 54 b.

The second sheet of material 60 b has an inner perimeter 62 b, an innerarea 63 b surrounded by the inner perimeter 62 b substantially sized andshaped to mate with the inner perimeter 52 b and inner area 53 b,respectively, of the first sheet of material 50 b such that as the firstsheet of material 50 b and the second sheet of material 60 b aredisposed in a coplanar, parallel and aligned configuration the sealingof the inner perimeter 52 b of the first sheet of material 50 b to theinner perimeter 62 b of the second sheet of material 60 b provides theinner seal 44 b for the flexible inflatable substrate 40 b. In oneembodiment the second sheet of material 60 b also has an outerperipheral edge 64 b and an outer area 66 b between the inner perimeter62 b and outer peripheral edge 64 b. The outer area 56 b of the firstsheet of material 50 b can be bonded to the outer area 66 b of thesecond sheet of material 60 b to provide the decorative extension 12 bfor the inflatable packaging material 10 b and the outer peripheral edge54 b of the first sheet of material 50 b and the outer peripheral edge64 b of the second sheet of material 60 b provides the distal edge 45 bfor the flexible inflatable substrate 40 b. The inner perimeter 52 b ofthe first sheet of material 50 b can be sealed via bonding or weldingthe inner perimeter 66 b of the second sheet of material 60 b to provideand define an expandable interior inflation space 100 b. A means 110 bfor inflating similar in construction to the means 110 for inflating,previously described herein, is disposed within the expandable interiorinflation space 100 b. The flexible inflatable substrate 40 b isinflated by the means 110 b for inflation.

Although the flexible inflatable substrate 40 b is shown in FIGS. 12-14as having the inner area 43 b being substantially round and the distaledge 45 b being scalloped, the inner area 43 b and the distal edge 45 bof the flexible inflatable substrate 40 b may be any shape. For example,the inner area 43 b and/or the distal edge of the flexible inflatablesubstrate 45 b may be square, rectangular, oval, oblong, triangular,hexagonal or any other geometric or fanciful shape. The distal edge 45 bof the flexible inflatable substrate 40 b may also be any shape or evenhave an irregular, capricious or decorative shape. The tuft 20 b isattached to the exterior surface 120 b of the flexible inflatablesubstrate 40 b in substantially the same way as the tuft 20 is attachedto the flexible inflatable substrate 40. The tuft 20 b can be sized andconfigured to cover all or only a portion of the exterior surface 120 bof the flexible inflatable substrate 40 b. The tuft 20 b can also besized, configured and disposed to cover all or a portion of thedecorative extension 12 b.

FIG. 14 illustrates one use of the inflatable packaging material 10 bdescribed above. The inflatable packaging material 10 b is shown in itsinflated condition after the means 110 b for inflating has beenactivated (i.e. the expandable interior inflation space 100 b isinflated) and is disposed in a basket 220 b to support a plurality ofarticles or objects 230 b, such as candies or Easter eggs, for display.More specifically, the inflatable packaging material 10 b is positionedin an interior 240 b of the basket 220 b such that the inner area 43 bof the flexible inflatable substrate 40 b substantially conforms to thecontour of the interior 240 b of the basket 220 b thereby lining theinterior 240 b of the basket 220 b with the individual strips, strands,or units of material 30 b forming the tuft 20 b that is bonded to theflexible inflatable substrate 40 b to form the inflatable packagingmaterial 10 b and the decorative extension 12 b extends generally abovean upper edge 242 b of the basket 220 b. If the second sheet of material60 b of the flexible inflatable substrate 40 b is provided with thebonding material 22 b, the second sheet of material 60 b of the flexibleinflatable substrate 40 b can be bondably connected to the interior 240b of the basket 220 b. In addition, the bonding material 22 b on thesecond sheet of material 60 b of the flexible inflatable substrate 40 bcauses the inflatable packaging material 10 b to remain in place in thebasket 220 b. If the second sheet of material 60 b of the flexibleinflatable substrate 40 b is not provided with the bonding material 22b, the flexible inflatable substrate 40 b simply rests in the interior240 b of the basket 220 b.

Referring now to FIG. 15 shown therein is a packaging material 500constructed in accordance with the present invention. The packagingmaterial 500 includes a substratum 504 and a printed pattern 506simulating a grasslike pattern disposed on at least a portion of thesubstratum 504 so as to provide the substratum with a grasslikeappearance. Although the substratum 504 is shown in FIG. 15 asrectangular, the substratum 504 may be any shape. For example, thesubstratum 504 may be square, triangular, hexagonal, circular or anyother geometric shape. The substratum 504 may even have an irregular ornon-linear, capricious or decorative shape.

The substratum 504 can be constructed of any non-inflatable cushioningand/or resilient type of material capable of supporting and cushioningan object such as sponge-like material such as, by way of example butnot limitation, natural sponge, artificial sponge, polymeric material,cloth, paper, cardboard, cellulose, paper mache or combinations,derivations and laminations thereof. The substratum 504 may beconstructed of a single layer of material or a plurality of layers ofthe same or different types of material. In addition, any thickness ofsubstratum 504 may be utilized in the present invention. Preferably, thesubstratum 504 is substantially conformable to the general contour of aninterior surface 507 of a container 508 and the substratum 504 iscapable of supporting and cushioning an object 510 disposed on thesubstratum 504. A plurality of the substratum 504 may be disposed in thecontainer 508. The plurality of the substratum 504 is preferablysubstantially conformable to the general contour of the interior surface507 of the container 508 and capable of cushioning the object 510supported by the plurality of the substratum 504.

The substratum 504 can also be embossed so as to provide the substratum504 with an embossed pattern 512. The embossed pattern 512 can be eitherin register or out of register with the printed pattern 506. Theembossing can cover all or only a portion of the substratum 504.

Different colors can be employed to provide the printed pattern 506 onthe substratum 504. The printed pattern 506 can be disposed on theentire exterior surface 516 of the substratum 504 or the printed pattern506 can be disposed on only a portion of the substratum 504.

A bonding material 520 may be applied to all or at least a portion ofthe substratum 504. The term “bonding material” as used herein can meanan adhesive, frequently a pressure sensitive adhesive, or a cohesive orany adhesive/cohesive combination having adhesive qualities (i.e.,qualities of adhesion or adhesion/cohesion, respectively) sufficient toaffect the connection between portions of the substratum 504 andportions of the container 508 and/or an object supported by thesubstratum 504 brought into engagement with the substratum 504. It willbe appreciated that both adhesives and cohesives, for the purposesdescribed herein, are well-known in the art, and commercially available.

The bonding material 520 may be applied in such a manner so as tosubstantially coat only a first surface 524 or only a second surface 528of the substratum 504. It will further be appreciated that the bondingmaterial 520 may be disposed on the first surface 524 and/or the secondsurface 528 in any variety of patterns such as strips, circles, dots, orany other geometric or biomorphic shape, including decorative designs solong as the bonding material 520 is positioned to function in accordancewith the present invention.

The printed pattern 506 may be any printed pattern or any pictorialrepresentational color or shape, such as a printed pattern simulatingthe grass-like appearance of the tuft 20 c such that when a small amountof the plurality of individual strips strands, or units of material 30 cforming a tuft 20 c are bonded to the substratum 504, the printedpattern 506 fills voids between the plurality of individual strips,strands or units of material 30 c such that it provides the illusionthat there are few or no actual voids of the plurality of individualstrips, strands or units of material 30 c on the substratum 504 therebyresulting in an aesthetically pleasing packaging material 500 thatappears to be fully covered with the individual strips, strands, orunits of material 30 c.

The packaging material 500 can also include at least one decorativeextension 532 that extends outwardly from at least a portion of thesubstratum 504. The decorative extension 532 can be fabricated from anysheet of material including but not limited to paper, crepe paper,polymeric film, laminated polymeric film, cardboard, paper mache, clothor combinations, laminations, and derivations thereof. The decorativeextension 532 can include an interior expandable space 533 and a meansfor inflating the interior expandable space 533 so as to allow thedecorative border 532 to be inflatable. The decorative extension 532 caninclude printing 536 disposed on at least a portion of the decorativeextension 532. The decorative extension 532 can also include embossing540. Printing 536 and embossing 540 on the decorative extension 532 canbe in register or out of register. Different colors can be employed toprovide the printing 536 on the decorative extension 532. The decorativeextension 532 can extend entirely around substratum 504 or thedecorative extension 532 can extend only around a portion of thesubstratum 504. Although the shape of the decorative extension 532 isshown as substantially scalloped the shape of the decorative extension532 can be any geometric, or non-geometric, or linear, or non-lineardecorative or even fanciful shape. All or a portion of the decorativeextension 532 can be bonded to the substratum 504 or frictionallysecured to the substratum 504. Furthermore, the decorative extension 532can be secured to the substratum 504 via securing elements such as byway of example but not limitation rubber bands, elastic bands, clips,thread, twine, string, cloth or staples or combinations and derivationsthereof. The decorative extension 532 can be sized, shaped, andconfigured such that the decorative extension 532 extends above thecontainer 508 into which the substratum 504 and the decorative extension532 are disposed or the decorative extension 532 can be sized, shapedand configured such that the decorative extension 532 is even with orbelow the container 508 into which the substratum 504 and the decorativeextension 532 are disposed. The decorative extension 532 can include ameans for conveniently removing the decorative extension 532 from thesubstratum 504 via a detaching element such as a tear strip, score lineor a plurality of perforations.

Referring now to FIG. 16 shown therein is packaging material 600 similarto the packaging material 500. The packaging material 600 includes asubstratum 604 similar to the substratum 504, except the substratum 604does not include the printing 508. The packaging material 600 doesinclude individual strips, strands or units of material 30 d disposed onthe substratum 604. The individual strips, strands or units of material30 d can be bondably connected to the substratum 604. The packagingmaterial 600 can also include at least one decorative extension 610,similar to the decorative extension 532, bonded to the substratum 604 orfrictionally connected to the substratum 604 or secured to thesubstratum 604 via the securing elements such as elastic bands, rubberbands, strips of cloth, staples, twine, or string or otherwise at leastpartially secured or associated with the substratum 604. The decorativeextension 610 can include a printed pattern 612 similar to the printedpattern 536 and embossing 614 similar to the embossing 540.

The individual strips, strands or units of material 30 d can beintertwined to form a cohesive mass of strips, strands and units ofmaterial 20 d for connection to or disposition on the substratum 604 orthe individual strips, strands and units of material 30 d can include abonding material disposed on at least a portion of the mass ofindividual strips, strands and units of material to form a cohesive massof strips, strands and units of material connected to the substratum604. Furthermore, the individual strips, strands or units of material 30d can be both intertwined and include the bonding material to form acohesive mass of strips, strands and units of material 20 d connected tothe substratum 604.

Referring now to FIG. 17 shown therein is a packaging material 700similar to the packaging material 500 and the packaging material 600.The packaging material 700 includes a substratum 704 adapted to supportand/or cushion at least one object 706. The substratum 704 includes atleast one depression 708 sized and configured to receive at least aportion 710 of the object 706. The packaging material 700 can alsoinclude a decorative extension 714 similar to the decorative extension532 and the decorative extension 632. The decorative extension 714 caninclude printing and embossing similar to the printing and embossing onthe decorative extensions 532 and 632 of packaging material 500 andpackaging material 600, respectively. The packaging material 700 alsoincludes the mass of individual strips, strands or units of material 30e connected to the substratum 704. In one embodiment of the packagingmaterial 700 the at least one depression 708 is substantiallysemi-elliptically configured, sized and shaped to receive at least aportion of at least one substantially egg-shaped object 706.

FIG. 18 illustrates one use of the packaging material 700. The packagingmaterial 700 is positioned in an interior 740 of a basket 750 such thatthe substratum 704 substantially conforms to the general contour of theinterior 740 of the basket 750 thereby lining the interior 740 of thebasket 750 and providing the at least one depression 708 in thesubstratum 704 sized and configured to receive at least a portion 710 ofat least one substantially egg shaped object 706 disposed in thedepression 708 of the substratum 704. Surrounding the substantiallyegg-shaped object 706 disposed in the depression 708 of the substratum704 is the mass of individual strips, strands or units of material 30 eso as to provide a pleasing and decorative appearance. The decorativeextension 714 extends outwardly from the substratum 704 to add to theoverall decorative effect. The individual strips, strands or units ofmaterial 30 e can be constructed of at least one clear layer ofpolymeric film laminated to at least one layer of iridescent polymericfilm so as to provide an iridescent effect to the packaging material700. The packaging material 700 can be secured to the basket 750 viabonding material or securing elements or the packaging material 700 canbe secured to the basket 750 via a combination of bonding materials,securing elements and/or frictionally secured.

From the above description it is clear that the present invention iswell adapted to carry out the objects and to attain the advantagesmentioned herein as well as those inherent in the invention. Whilepresently preferred embodiments of the invention have been described forpurposes of this disclosure, it will be understood that numerous changesmay be made which will readily suggest themselves to those skilled inthe art and which are accomplished within the spirit of the inventiondisclosed and as defined in the appended claims.

1. A packaging material, comprising: a substratum adapted to support an object; and, a printed pattern disposed on at least a portion of the substratum to provide the substratum with a grass-like appearance.
 2. The packaging material of claim 1 wherein the substratum further includes an embossed pattern on at least a portion of the substratum.
 3. The packaging material of claim 1 further including a decorative extension extending outwardly from at least a portion of the substratum.
 4. The packaging material of claim 3 wherein the decorative extension is inflatable.
 5. The packaging material of claim 3 wherein the decorative extension includes embossing on at least a portion of the decorative extension.
 6. The packaging material of claim 3 further including a printed pattern simulating the appearance of decorative grass disposed on at least a portion of the decorative extension.
 7. The packaging material of claim 1 wherein the substratum is constructed of sponge-like material.
 8. The packaging material of claim 1 further including a mass of individual strips, strands or units of material connected to the substratum.
 9. The packaging material of claim 8 wherein the packing material further includes a bonding material disposed on the mass of individual strips, strands or units of material to form a cohesive mass of strips, strands and units of material connected to the substratum.
 10. The packaging material of claim 9 wherein the of individual strips, strands or units of material are intertwined to form a cohesive mass of strips, strands and units of material connected to the substratum.
 11. A packaging material, comprising: a substratum adapted to support an object; and, a mass of individual strips, strands, or units of material connected to the substratum.
 12. The packaging material of claim 11 further including a decorative extension extending outwardly from at least a portion of the substratum.
 13. The packaging material of claim 12 further including at least one of printing and embossing on at least a portion of the decorative extension.
 14. The packaging material of claim 11 wherein the substratum further includes an embossed pattern on at least a portion of the substratum.
 15. The packaging material of claim 11 wherein the substratum is constructed of sponge-like material.
 16. The packaging material of claim 24 wherein the packing material further includes a bonding material disposed on the mass of individual strips, strands or units of material to form a cohesive mass of strips, strands and units of material connected to the substratum.
 17. A packaging material, comprising: a substratum adapted to support at least one object, at least one depression in the substratum, the at least one depression sized and configured to receive at least a portion of the at least one object; and a mass of individual strips, strands or units of material connected to the substratum.
 18. The packaging material of claim 17 wherein the packaging material further includes printed pattern simulating the appearance of decorative grass disposed on the substratum.
 19. The packaging material of claim 17 further including an embossed pattern connected to the substratum.
 20. The packaging material of claim 17 further including a decorative extension extending outwardly from the substratum.
 21. The packaging material of claim 17 wherein the packing material further includes a bonding material disposed on the mass of individual strips, strands or units of material to form a cohesive mass of strips, strands and units of material connected to the substratum.
 22. The packaging material of claim 17 wherein the depression is substantially elliptically configured and sized to receive at least a portion of at least one substantially egg-shaped object.
 23. A method of packaging an object, comprising the steps of: providing a packaging material comprising at least one of: (a) a substratum adapted to support an object; a printed pattern disposed on at least a portion of the substratum to provide the substratum with a grass-like appearance; (b) a substratum adapted to support an object; a mass of individual strips, strands, or units of material connected to the substratum; and, disposing an object on the packaging material, whereby the packing material supports and cushions the object.
 24. A method of packaging an object, comprising the steps of: providing a packaging material comprising: a substratum adapted to support at least one object, at least one depression in the substratum, the at least one depression sized and configured to receive at least a portion of the at least one object; a mass of individual strips, strands or units of material connected to the substratum; and, disposing an objection on the packaging material such that at least a portion of the object is disposed in the at least one depression in the substratum of the packaging material. 